FRANK Spacer Technology · FRANK ﬁ bre concrete spacers match all of the above requirements and more. Applications for Standard and Premium grade fibre-reinforced concrete spacers

Technologies for the construct ion industr y

FR A N K S p a c e r Te c h n o l o g y

Max Frank GmbH & Co. KG

Mitterweg 1

94339 Leiblfi ng

Germany

Tel. +49 9427 189-0

Fax +49 94 27 15 88

[email protected]

www.maxfrank.com

2

Technologies for the construct ion industr y 3

Page Product Application

4

5

Frank spacers – more than 45 years experience

Spacers - the benefi ts of fi bre concrete

A B C

6 - 7 Applications

8

9

Standards

Recommendations for number and location

10 - 11 Summary of features

12

13 - 15

Single spacers – the benefi ts

Applications

16

17 - 19

Bar spacers - the benefi ts

Applications

20

21

22 - 23

Special spacers – the benefi ts

Applications

Special Spacers - high durability applications

24

25

U-Korb continuous high chairs – the benefi ts

U-Korb continuous high chairs – dimensioning and application

26

27

28 - 29

Distance tubes – the benefi ts

Distance tubes – application

Distance tubes for seals (watertight, sound proof and fi reproof)

30

31

32 - 33

Sealing cones – the benefi ts

Applications

Shutter ties – special versions

34 - 35 Products for drinking water applications

36

37

Plastic products – spacers and distance tubes

Plastic products – line spacers and profi les

38

39

Test certifi cates

Reference projects

Spacer Technology Tab le of contents

fix

ing

co

ve

r c

v o

f re

info

rce

me

nt

4

FRANK spacers More than 45 years exper ience

Spacers made of fibre concreteThe correct quality and depth of concrete cover to the reinforcement is of great importance, both for the durability of rein-

forced and prestressed concrete structures and for their fi re resistance. According to EN1992-1-1:2004 Design of concrete

structures. General rules for building “the reinforcement is to be placed with a fi xing cover cv, so that there is a high degree

of probability that the minimum reinforcement cover cmin

is achieved”. For this spacers are required to maintain cover before

and during concreting and they must not affect the serviceability and durability of the structural member after concreting.

FRANK fi bre concrete spacers match all of the above requirements and more.

Applications for Standard and Premium grade fibre-reinforced concrete spacersThis chart allows you to select the appropriate grade of spacers.

ApplicationMaterial quality

Standard Premium

Structural elements with normal durability requirements yes no

Structural elements with higher durability requirements no yes

Resistance to high levels of sulphate no yes*

Acid resistance (down to pH = 2) no yes*

Approved for potable water use yes** no

Resistance to fi re yes yes

White cement or colour mixtures no yes*

Specifi c customer requirements no yes** Premium grade is adapted for specialist applications** Standard grade is adapted for this application

Quality fibre concrete spacers with different propertiesWe manufacture spacers to meet your requirements.

■ DurabilityProtection of reinforcement against carbonation, chloride

ingress and other aggressive substances

■ StabilitySafe transmission of static forces into the concrete

■ Fire resistanceProtection of reinforcement against high temperatures

during fi re events

45 years experience in the

manufacture and site use of fibre

concrete spacers and distance tubes.

Material quality “Standard”

Spacer properties match the standard requirements of

most international specifi cations.

Certifi ed to most international standards

(DIN, BS, etc.).

Material quality “Premium”

Spacer properties match the highest durability

requirements of most international specifi cations.

Certifi ed to most international standards

(DIN, BS, etc.).

In addition to the “Standard” and “Premium” grades, we can, upon request also manufacture as part of our spacer

production programme “Basic” grade. “Basic” grade can be used for applications where the strength and durability benefi ts

of standard or premium grade products are not required.


Fibre concrete – the optimum material

in combination with in-situ concrete

■ Consistent high compressive strength with

resistance to tilting

■ Excellent bond with in-situ concrete – no

hairline cracks between the spacer and the

concrete

■ Extremely suitable for impermeable concrete

■ Excellent physical and chemical resistance

■ Fire resistant to the highest requirements

specified in EN 13501-1:2002 – class A1

■ Consistent and accurate dimensional tole-

rances and do not deform under temperature

fluctuations

■ Quick and easy installation with a number of

fixing options

■ Spacers with special dimensions and shapes

can be manufactured at short notice

■ Manufactured in accordance with

EN ISO 9001: 2000

Spacers The benef i ts of f ib re concrete

Formwork panel – fi bre concrete permanent formwork

Zemdrain® – Controlled Permeability Formwork Liner

6

Spacers App l icat ion

Construction Sites

Spacers for all construction

applications

Precast Plants

Spacers for lightly loaded applications

Wastewater Works

Spacers for acidic environments

Bar spacers Distance tubesSealing cones Single spacers

Permanent fl oor/edge insulating formwork

Permanent fl oor/edge formwork

Egcobox® – insulated balcony connector

Stremaform®


Spacers App l icat ion

Tunnel construction

Secure fi xing in any position even with

overhanging reinforcement

Exposed concrete

Products meeting highest architectural

requirements (colour and exposure)

Drinking water applications

Certifi ed products for use in drinking

water applications

U-Korb continuous high chairs

Bar spacers

8

FRANK has stood for quality and customer-oriented

solutions for more than 45 years.

You should observe the

following when selecting

spacers:

■ Instructions for selection of the

appropriate spacer with reference

to the exposure class according

to EN206-1:1997 and other

international standards

■ Instructions for selection of the

appropriate spacer depending

on the type of structural element

and on the type of spacer

according to appropriate

international standards

■ Required concrete cover

according to EN1992-1-1:2004

nominal dimension of installation

of concrete cover cnom

■ Spacer loading due to

reinforcement weight and

additional loads, e.g. during

concreting, installation of steel

mesh and preassembled

structures

■ Diameter and location of the

reinforcement – wall/slab

■ Type of reinforcement – single bar

or mats

■ Simple, rapid and economical

fi xing

■ Type of fi xing – without tying

wire, with tying wire, with steel or

synthetic clips

■ External infl uences affecting

the concrete, such as pressure,

temperature, chemical attack,

alternating moisture penetration,

fi re and corrosion

■ Treatment of concrete surface

(stucco work)

■ Exposed concrete – possible

imprint left by spacers on the

concrete surface

Spacers are used to ensure that the concrete cover specified

for structures and structural elements made of reinforced

concrete is adhered to, both before and during concreting.

Marking of spacers according to German Society for concrete and

construction technology (DBV) data sheet

Spacers certifi ed to DBV data sheet must be marked as follows:

DBV – c – L/F/T/A/D

These abbreviations mean:

For normal requirements:

DBV - This spacer fulfi ls the requirements of the present data sheet

c - fi xing cover for reinforcement cv (mm)

L - performance classes

L1 = no increased requirements with regard to load-bearing capacity and tilting

stability, e.g. reinforcement not subject to foot traffi c

L2 = increased requirements with regard to load-bearing capacity and tilting

stability – used as standard spacers in in-situ concrete

Products certifi ed to DBV-c-L/F/T/A/D are marked in our documentation.

Please ask for the corresponding test reports if required.

Mermber of the European Concrete Society Network (ECSN).

For special requirements:

F - increased freeze-thaw resistance

T - suitable for structural elements subject to extreme temperature variations

A - watertight and resistant to chemical attack

D - permissible reinforcement bar diameter range for the spacer (if necessary)

■ Spacers with simple cover concrete cover 15 + 20 fulfi l

performance class L1: DBV – c – L1

■ Spacers with simple cover concrete cover as of 25 mm fulfi l

performance class L2: DBV – c – L2

■ Spacers with multiple cover are certifi ed to DBV data sheet, however,

application of DBV marking is not possible for them, as they have two or

three different concrete covers.

■ The same applies for bar spacers with lengths > 35 cm.

Spacers Standards

Consider defl ection of thin supporting bars during concreting. Check resistance of spacers to extra loading for

heavy reinforcement.

The fi xing interval is based primarily on the accepted defl ection at maximum loading, e.g. when the reinforcement is walked

on especially during concreting. When placing bar spacers in the tension zone, we also recommend the use of short lengths

staggered across the formwork.


point-supporting spacers

b

S2

hS2

nom cvnom cv

S1

nom cvnom cv

Structural element: beams and columns

Spacer fi xing distances max. S1 in longitudinal direction

Bar diameter dS

Columns Beams

≤ 10 mm 0.50 m 0.25 m

12 to 20 mm 1.00 m 0.50 m

> 20 mm 1.25 m 0.75 m

Spacer fi xing distances max. S2 in transverse direction

Quantity, distances

b or h Columns Beams

≤ 1.00 m 2 pieces 2 pieces

> 1.00 m ≥ 3 pieces ≥ 3 pieces

max. S2

0.75 m 0.50 m

S

no

m c

vn

om

cv


Structural element: slabs

Spacer fi xing distances S

Supporting max. Required quantity m2

bar diameter S Single spacer Bar spacer

dS

L = 0.18 m L = 0.33 m L = 1.00 m

≤ 6.5 mm 0.50 m 4 3.0 2.5 1.33

> 6.5 mm 0.70 m 2 1.6 1.4 0.84

vibrator channel


S1

S1

nom cv nom cv

Structural element: walls

Spacer fi xing distances S1 and number per m2 of wall

Supporting max. Required quantity m2 wall1)

bars S1

Single spacers Bar spacers

dS

L = 0.18 m L = 0.33 m

≤ 8 mm 0.70 m 4 1.6 1.4

> 10 mm 1.00 m 2 1.0 0.8

1) and per wall side

Spacers Recommendat ions fo r number and locat ion

10

Single spacers Summar y of featu res

Without tying wire

With tying wire

With steel clips

With transverse

clip

With plastic

clip

Combined spacers

With plastic rail

With structural steel rail

Type of products AO AD AK AK-Q AC KOMBI KOMBST

Drawing

Horizontal reinforcement

1)

Vertical reinforcement

1)

1)

1)

1)

Exposed concrete

Group type2) B1 B2 B2 B2 B2 C1 C1

suitable

1) provided that tilting or displacement is not possible

2) group type according to DBV data sheet “spacers” B1 = point-supporting, not fixed B2 = point-supporting, fixed C1 = linear-supporting, not fixed C2 = linear-supporting, fixed

3) Certified to the requirements of the DBV data sheet “spacers”: F = increased freeze-thaw resistance T = Suitability for structural elements subject to extreme temperature variations A = watertight and resistant to chemical attack

conditionally suitable

not suitable

Single spacers

The use of spacers manufactured from fi bre concrete ensures that the concrete

cover specifi ed for structures and structural elements made of reinforced concrete is

adhered to, both before and during concreting.

We offer you the optimum spacer for every application.

Material quality Standard Premium

Concrete cover mm 15 – 100 (other dimensions are possible) 20 – 100

Load-bearing capacity N > 3000 > 3000

Performance class P2 P2

Compressive strength N/mm2 50 60 (> 100 N/mm2 can be produced)

Permitted deformations mm < 1 < 1

Permitted tolerances mm ± 1 ± 1

Water absorption % after 30 min < 3 < 2

Exposure class4) X0/XC/XD/XS/XF/XA X0/XC/XD/XS/XF/XA

Construction materials class A1 – not fl ammable A1 – not fl ammable

Fire resistance class F30 – F180 F30 – F180

Requirement CS3) F / T / A F / T / A

I.S.A.T (after 10 sec.) ml/m2/sec < 0.5 < 0.25

Chloride diffusion m2/sec x 10 -12 < 5.0 < 1.0

Rapid chloride permeability (RCP) coulomb n/a < 1000 (very low)

Adhesion to concrete N/mm2 0.4 0.4


TriangularTriangular concave

Triangular concave

with hook

Triangular concave

with tying wire

Square RoundSnake

+ Snake N

Banana +

Banana NRail

FAHD FAHK FAHDH FAHKZD FAHV FAHR FAHKS FAHKB FAHSS

N N

5)

5)

5)

5)

5)

5)

5)

C1 C1 C2 C2 C1 C1 C1 C1 C1

4) Exposure class to EN 206-1:2001 XC = Carbonation XD = Chlorides (except for sea water) XS = Chlorides from sea water XF = Frost with / without thawing agent XA = Chemical attack

5) with longitudinal dead limit (350 mm or ≤ 2 x h or ≤ 0,25 x b, whereby h = structural element thickness and b = structural element width).

Bar spacers

The excellent material properties of fi bre concrete ensure high compressive strength,

impermeability to water, fi re resistance, application stability and thus guarantee the

durability of the concrete surface. The shape and design of our bar spacers provides

for safe and cost-effective use on site.

Bar spacers Summar y of featu res

Material quality Standard Premium

Concrete cover mm 15 – 100 (other dimensions are possible) 20 – 100

Load-bearing capacity N > 3000 > 3000

Performance class P2 P2

Compressive strength N/mm2 50 60 (> 100 N/mm2 can be produced)

Permitted deformations mm < 2 < 2

Permitted tolerances mm ± 1 ± 1

Water absorption % after 30 min < 3 < 2

Exposure class4) X0/XC/XD/XS/XF/XA X0/XC/XD/XS/XF/XA

Construction materials class A1 – not fl ammable A1 – not fl ammable

Fire resistance class F30 – F180 F30 – F180

Requirement DBV3) F / T / A F / T / A

I.S.A.T (after 10 sec.) ml/m2/sec < 0.5 < 0.25

Chloride diffusion m2/sec x 10 -12 < 5.0 < 1.0

Rapid chloride permeability (RCP) coulomb n/a < 1000 (very low)

Adhesion to concrete N/mm2 0.4 0.4

Our complete programme of single spacers and bar spacers is manufactured in “Standard” material quality.

Material qualities “Basic” and “Premium” are manufactured on request.

12

Single spacers The benef i ts

Single spacers

Fibre concrete, the optimum material in combination

with in-situ concrete

■ High compressive strength, no deformation in heat or cold, the required

concrete cover will be accurately retained

■ The spacers remain in position during formwork erection and concrete

placement

■ Eminently suitable for impermeable concrete as hairline cracks do not

develop between the spacer and the concrete

Single spacers are used to ensure that the specifi ed concrete cover for structures and structural elements made

of reinforced concrete is adhered to, both before and during concrete placement.


Single spacers App l icat ion

Spacers without tying wire

For horizontal reinforcement

Spacer type 4013 without tying wire – can be used for horizontal single bar

reinforcement or mesh reinforcement.

Spacers with tying wire

For horizontal and vertical reinforcement

Spacer type 3572 D – this type of multi-cover spacer gives the option of

reduced stock levels

Spacers with steel clips

For vertical reinforcement

Spacer type ZS with 2 steel clips guarantees the fastest possible fi xing

time and thanks to the preformed groove an exact and secure seating of

the reinforcement.

Spacers with cross-clips

For vertical reinforcement

Spacers with cross-clips – secure fi xing at the crossing point for vertical

reinforcement by means of a 2 mm thick steel clip and the preformed groove.

14

Spacers with plastic clips

No tying wire within the concrete cover

Spacers with plastic clips guarantee a secure and exact concrete cover - no

metal parts within the concrete cover.

Spacers with shuttlecock clips

No tying wire within the concrete cover

Spacers with shuttlecock clips secure the exact concrete cover for reinforcing

steel mesh or reinforcement not subject to foot traffi c, e.g. in a precast plant.

Spacers for concrete pipe production

For centring of reinforcement cages

Spacers for concrete pipe production – fi xed to both internal and external

concrete pipe reinforcement.

Reinforcement end supports

Used as stands for vertical single rebars

Just press onto rebar end – self-clipping; very high loading capacity – cannot

tip over.



RONDO round spacer with metal clip

For use with prefabricated reinforcement cages

Round spacers help to minimise damage to the formwork face during

installation of the reinforcement.

Spacers for fire protection reinforcement

In tunnel constructions

The fi re protection spacer made of fi bre concrete is used in tunnel constructions

to provide simultaneously for an appropriate concrete cover of the fi re protection

reinforcement and of the supporting reinforcement.

Fire protection reinforcement prevents spalling of the concrete surface during

fi re events.

Combined spacers with plastic rail

For reinforcement not subject to foot traffi c in a precast plant

Ideal for exposed concrete applications due to reduced contact with form-

work.

Combined spacer with structural steel rail

For reinforcement not subject to foot traffi c in a precast plant and on

the construction site

Ideal for exposed concrete applications due to reduced contact with form-

work.


16

Bar spacers The benef i ts

Bar spacers made of fibre concrete

Fibre concrete – the optimum material in combination

with in-situ concrete

■ High compressive strength, no deformation in heat or cold, the required

concrete cover will be absolutely retained

■ Eminently suitable for impermeable concrete as hairline cracks do not develop

between the spacer and the concrete

■ Large support area – reduces penetration into support layer

■ Substantial labour cost savings due to the rapid and simple laying

■ Fire resistant to the highest requirements specifi ed in EN 13501-1:2002 –

Class 1A (not fl ammable)

Bar spacers are used to ensure that the concrete cover specifi ed for structures and structural elements made

of reinforced concrete is adhered to, both before and during concreting.

co

ncre

te

co

ver

support width


Bar spacers App l icat ion

Triangular bar spacers

For horizontal mesh and rod reinforcement – made with continuous

reinforcing fi bres

Application stability – triangular bar spacers always provide the same concrete

cover in any position.

Triangular concave bar spacers

For horizontal mesh and rod reinforcement – lightweight version made

with continuous reinforcing fi bres

Triangular concave bar spacers do not provide the same concrete cover in

every position they are placed. If there is a danger that they will tip over, you

should use triangular bar spacers instead.

Triangular concave bar spacers with hook clip

For vertical mesh and rod reinforcement

Simply clip to reinforcement.

Triangular concave bar spacers

with two tying wires

For secure fi xing in any position

Secure fi xing in any position, even with overhanging

reinforcement (tunnel construction).

Bar spacers can be held in position using

either one or two wires.

Non-tipping due to the large support width.

18

Square bar spacers

For heavy horizontal reinforcement – made with continuous

reinforcing fi bres

■ For particularly heavy reinforcement

■ Large supporting surface for use on deformable layers (insulation)

■ Non-tipping due to large support width

Round bar spacers

For horizontal reinforcement and exposed concrete – made with

continuous reinforcing fi bres

■ Eminently suitable for exposed concrete

■ For precast plants and construction sites

■ Almost invisible due to linear contact area

“Snake” type bar spacers

For horizontal mesh and rod reinforcement

■ Suitable for rapid and inexpensive fi xing of mesh and rod reinforcement

■ Stable and non-tipping, simple laying

“Snake N” type bar spacers with notches


■ Contact with the formwork is reduced to a few points due to the notched

contact surface.

■ Suitable for fi xing of single bar reinforcement when placed with overlaps.



“Banana” type bar spacers

For horizontal mesh reinforcement

■ Suitable for rapid and inexpensive fi xing of mesh reinforcement

■ Standard length 0.33 m specially made for R-mats and

standard length 0.25 m specially made for Q-mats provide

an optimum application stability and are non-tipping

“Banana N” type bar spacers with notches


■ Contact with the formwork is reduced to a few points due to the notched

surface.

■ Standard length 0.33 m specially made for R-mats and

standard length 0.25 m specially made for Q-mats provide

an optimum application stability and are non-tipping

“Rail” type bar spacers


■ Suitable for rapid and inexpensive fi xing of mesh reinforcement

■ Large supporting surface for insulation

“Rail B” type bar spacers


■ High load bearing capacity

■ Excellent bond to concrete

■ Protects formwork

■ Rapid and effi cient laying

■ Secure application


20

Special spacers The benef i ts

Special spacers

Spacers manufactured to special shape, size and

properties

■ Special shapes and dimensions can be produced quickly and effi ciently to

match your requirements.

■ Production in fi bre concrete is also possible in small quantities and with low

tooling costs

■ Special mixtures made of extremely sulphate resisting cement are available

■ Various colours can be produced using white cement or pigments

■ Compressive strengths of up to 100 N/mm² or greater are possible

■ Spacers with specifi c properties appropriate for individual site conditions:

- Highly acid-proof

- High resistance to freeze-thaw

- Reduced water absorption

Special spacers are manufactured quickly and effi ciently to meet your demands. We offer you numerous

technically accurate and inexpensive possibilities from supporting profi les for internal formwork in bridge-

building up to fi ligreed spacers.


Special spacers App l icat ion

Circular spacerFor rolling of large reinforcement cages into the correct position during short time periods.

Diaphragm wall spacersThe skid-shaped form allows the lowering of larger reinforcement elements without the risk of jamming.

Wedges and sealing cones for tunnel segmentsClosing of wedge sockets and cone holes in tunnel lining segments

Appropriate spacer solutions to specific problems

Our experience over 45 years enables us to arrive at the most appropriate solutions for your specifi c problems.

22

Spacers with higher compressive strength

Spacers with higher compressive strength are required for structures in which

they are subject to high loads during installation and concreting. With our fi bre

concrete quality “Premium” we are able to produce spacers with compressive

strengths > 100 N/mm².

Spacers with enhanced resistance

to Freeze/Thaw action

For structures such as bridges exposed to extreme freeze/thaw cycles we

can supply “Premium” grade spacers that are highly durable in this type of

environment.

Use of these spacers has been approved after testing in 400 alternating

freeze-thaw cycles, in accordance with the test on behaviour under exposure

to frost/de-icing agents for spacers, BE II FT visually, according to the D-R

method, issued by LPM AG, Beinwill am See, Switzerland.

Appropriate spacer solutions

for specific problems



Spacers with enhanced acid resistance

The special material composition of the “Premium SB” type spacers makes

them particularly acid-proof. “Premium SB” spacers are more stable than

conventional spacers and protect the reinforcement against acid attacks

over a longer time period and thus considerably extend the working life of

structures. This type of spacer is used for erection of cooling towers of

power plants.

Spacers with enhanced sulphate resistance

Structures exposed to chemical attack by sulphates require special highly

sulphate-resisting spacers. In accordance with EN206-1 these spacers may be

used for exposure classes XA2 and XA3.

Use of this type of “Premium” spacer made from sulphate-resisting cement

(SRPC) or a cement combination considerably extends and improves the

useful life of these structural elements.

We produce the appropriate spacer solution

for your specific application purpose.


24

U-Korb continuous high chairs The benef i ts

U-Korb continuous high chairs

U-Korb use ensures the correct cover

whilst protecting the formwork

■ Conforms to the requirements of European Concrete Societies Best Practice

Guide 2 – “Chairs for reinforcement”

■ Saves labour time and material due to rapid laying and a support width of 20 cm

■ Non-tipping due to a stable contact surface on the lower reinforcement

■ No contact with the formwork, therefore no damage to the formwork skin and

no rust stain formation on the concrete surface

■ Stable, when subject to foot traffi c due to the vertical uprights at the buckle

points of the continuous high chair

■ Suitable for use with both fi xing mats and single reinforcing bars

Continuous high chairs are used as spacers between the lower and upper reinforcement layers in bases,

slabs and walls. They fi x the distance between both reinforcement layers and hold them in the correct structural

position.


U-Korb continuous high chairs Dimens ion ing andapp l i cat ion

Designation according to German Society for Concrete and

Construction Technology (DBV) Guide to good Practice

DBV/EC2 = Continuous high chairs have been

tested and fulfi l the requirements of the

DBV data sheet

h = Continuous high chair height (in mm)

S = Stands on the reinforcement

L = Linear supporting chair

E.g. for orders CS-10-R-L

Bar diameter to be supported

Spacing intervalRequirement

approx. pieces/m2

ds ≤ 6,5 mm 500 mm 1,0

ds > 6,5 mm 700 mm 0,7

Determining the required quantity:

The following number of continuous high chairs are required

for normal construction loadings:

This table is only a guideline for determining the number

required. The exact spacing interval must always match

the requirements of the reinforcement and concrete cover

and must be checked on site. The decisive factor is the

defl ections that can be accepted when the reinforcement

is subject to foot traffi c (when concreting).

If the reinforcement is not subject to foot traffi c, such as

in precasting plants or when using continuous high chairs

for wall constructions, the required quantity determined as

above can be reduced by 10 – 20 % without problems.

h d

b2

a2

b1

a1

FRANK continuous high chair

FRANK bar spacer

h d

b2

a2

b1

a1

System construction “slab” + “base”

Support width 200 mm

Determination of the necessary chair height:

Determination of the necessary chair height taking the

required concrete cover and design slab thickness into

account

Required slab thickness “d” minus total “x” gives necessary

chair height “h”. In our example with a required slab thickness

of 200 mm: 200 – 80 = 120 m chair height. The chair height

corresponds with UKS12.

* please take mesh overlap into account

Example:

1. Lower reinforcement concrete cover a1 30 mm

2. Upper reinforcement concrete cover a2 20 mm

3. Lower reinforcement thickness* b1 15 mm

4. Upper reinforcement thickness* b2 15 mm

Total x 80 mm

26

Distance tubes The benef i ts

Distance tubes made of fibre concrete

The technically perfect solution for shutter ties

■ High compressive strength

■ Large contact area, therefore no pressing into the formwork

■ Conforms to EN1992-1-1:2004 (concrete and reinforced concrete) and to

DIN 18216 (formwork ties for concrete formwork)

■ Can be manufactured as impermeable shutter ties

■ Fire resistance class F30 – F180, suitable for fi re walls F90 to EN 13501-1:2002

■ Sound-proof due to glued stoppers

Distance tubes are used to secure the concrete wall thickness using reusable tie bars.


Distance tubes App l icat ion

Contact zone between the distance tube and the formwork face

There are four different methods of forming the transition between the distance tube and the formwork surface:

Distance tube directly butting the formwork

The bearing area for the most common distance tube (ø 22 standard wall

thickness) is 7 cm². According to DIN 18216 at least 5 cm² are required for a

compressive force of 1.5 kN. Although the bearing area is suffi cient according

to DIN 18216, we recommend the general use of sealing caps or cones.

Distance tube with sealing cap

(Normal design according to manufacturer’s recommendations).

Irregularities in the formwork face are evened out by the sealing cap and this

helps to prevent any cement slurry from running into the distance tube.

Distance tube with cone

Use of the cone allows the distance tube to be cast 10 mm deeper into the

wall which results in a permanent cone-shaped impression. This has the effect

of visually relieving the smooth concrete wall.

Distance tube with deep cone

The 30 mm to 50 mm long cone is often used as an aid for non right-angled

transitions, as it prevents twisting. Sometimes this does not require further

fi nishing, i.e. just one diagonal cut.

To ensure optimum performance always use Frank accessories with Frank distance tubes!

With sealing cap

With cone 10 mm

With cone 30/50 mm

Up to 0.40 m wall thickness

0.40 – 0.60 m wall thickness with centre coupling

over 0.60 m wall thicknessfor high loads

The appropriate distance tube system for every wall thickness

Distance tube Ø Tie bar Ø Nominal dimension

22 12.5

22 15.0

27 20.0

32 22.0

40 26.5

Tie

bar

ØN

omin

al d

imen

sion

Dis

tanc

e tu

be

Ø

Selection table tie bar

28

FRANK distance tubes can also be used in the construction of watertight

concrete structures.

Sealing of distance tubes with Frank mortar 3/25

Method 1

Insert the sealing cone on one face and

afterwards grout the distance tube from

the other side. After sealing fl oat the

surface.

Method 2

Grout the distance tube from both sides

and then fl oat the exposed face.

Method 3

Continuous grouting of distance tubes/

shutter ties. FRANK combined shut-

ter ties or distance tubes for larger walls

(thicker than around 1 m) should be grouted

using the extension nozzle from the inside

towards the outer surface.

Distance tube sealed with an FB stopper + Repoxal glue

Distance tube sealed with a speciality mortar

Alternative methods of

sealing distance tubes:

Distance tubes For sea ls(wate r t ight, sound proof and f i reproof )


Watertight/sound-proof seal

if one fi bre concrete sealing cone of

minimum length 50mm is used on each

side, no stoppers are required

Continuous seal/Fire Wall seal

using several stoppers completely fi ll

the tube and seal ends with sealing

cones


using Frank speciality mortar 3/25 –

injected from each side.


requires one fi bre concrete sealing

cone and one stopper on each side.

Normal seal

Only requires one stopper on each

side.


requires two stoppers on each side.

Sealing options

Installation of FRANK stoppers in distance tube using Repoxal two-component glue

1) When inserting stoppers always start

from the side that is subject to water

pressure

2) Dip the fi rst stopper into the glue

and rotate it briefl y so that it is com-

pletely immersed around its circum-

ference. Then insert it and ensure

that this fi rst stopper is approx. 10

mm below the wall surface.

3) After that insert the second stopper

(also immersed in glue) and drive it in

until fl ush with the wall surface, then

distribute/remove excess glue.

4) These stoppers should then be left

to harden for a few hours. After this

period you can start from the other

side in a similar manner using two

stoppers.

Distance tubes For sea ls(wate r t ight, sound proof and f i reproof )

30

Sealing cones The benef i ts

Sealing cones made of fibre concrete

Individual design of concrete surfaces

■ Unique design possibilities

■ High dimensional accuracy

■ Quick and proper sealing of form tie holes

■ Smooth surface of low porosity

■ Exposed concrete quality to the highest standards

■ Can be produced in many different colours

■ Watertight seal of structures

Due to the numerous design

possibilities available to them,

architects and designers are

increasingly focusing on exposed

concrete for their construction

projects. Coloured or smooth

exposed concrete surfaces have

nowadays become decisive

features of modern architecture.


Sealing cones App l icat ion

Distance tube installation

Deep plastic cones ø 22 mm are

assembled with the distance tube and

installed in the formwork.

The holes used for shutter ties can be decisively impor-

tant. They can have a damaging impact on the overall

concept of an aesthetical striking high-quality structure, unless

they are of excellent design and perfectly sealed. There are

presently no binding rules worldwide to defi ne basic

“exposed concrete” features. However, the characteristics of

exposed concrete surfaces should always be in accordance

with accepted best practice.

The use of FRANK plastic caps and cones in conjunction with

our fi bre concrete distance tubes helps to prevent bleeding of

concrete into the shutter ties. The dimensions of Frank fi bre

concrete cones exactly match those of the FRANK plastic

cones. This ensures a tight and accurate fi t to give the best

surface appearance. Special dimensions and shapes of cones

for exposed concrete can be manufactured upon request.

Distance tube with

deep cone Ø 22 mm

Distance tube after formwork

removal

After stripping-off the formwork, the

deep plastic cones Ø 22 mm are

extracted from the distance tube using

the special cone pull-out device.

Cone hole sealing

Fibre concrete sealing cones are glued

in position fl ush with the wall on both

sides using Repoxal two-component

glue. A potable water approved version

of this glue is also available.

32

Shutter ties Spec ia l ve rs ions

Combined shutter tie with steel plate water stop

Distance tubes with glued-on

fi bre-concrete disks can be used

for shutter ties up to 0.60 m.

Distance tube with glued –on fibre concrete disk

For component thickness from

approximately 0.60 m upwards you

should use steel tubes coupled with

distance tubes of at least 100 mm

length on each side to ensure that

the required reinforced concrete wall

thickness is maintained.

The use of FRANK combined shutter

ties with cast-iron water stop is

particularly recommended when

the specifi cations prevent the use of

formwork ties, which leave behind a

continuous bore, such as ZTV-W.

Combined shutter tie with cast-iron water stop

FRANK plastic sealing cap or cone or deep cone

Steel tube

Steel plate water stop

glued

Distance tube made of fi bre concrete


FRANK distance tube made of fi bre-reinforced concrete

FRANK cast-iron water stop

FRANK coupling for cast-iron water stop


Fibre concrete disk

glued



Shutter ties Spec ia l ve rs ions

Distance tubes in two parts with coupler

Distance tubes in two parts are

used with wall thicknesses from

approx. 0.40 m up to 0.60 m to

avoid damage to the distance tube

caused by bending due to high

tensioning forces.

Sheet-steel water stop welded onto

anchor rod, combined with reusable

steel – plastic cones.

“Lost anchor” distance tubes

Construction of walls with internal

insulating plate / insulating board, for

acoustic separation of two wall disks.

“2-layer system” distance tubes


Coupler


Distance tube


Coupler

Assembly plate to be placed underneath

Insulating plate / insulating board


Steel – plastic cone

Anchor rod (lost part)

Sheet steel water stop

34

FRANK Products fo r d r ink ing wate r app l i cat ions

Single spacers made of fi bre concrete TW

Article number Concrete cover mm

AO3572TW 35/40/50

AO4573TW 45/55/60

AD3572TW 35/40/50

AD4572TW 45/55/50

AK40ZSTW 40

AK45ZSTW 45

AK50ZSTW 50

Distance tubes made of fi bre concrete TW

Article number Inside diameter mm Length m

MR221250TW 22 1,25

Stoppers made of fi bre concrete TW

Article number Diameter mm Length m

ST220020TW 22 20

ST220050TW 22 50

Sealing cones made of fi bre concrete TW For the sealing of conical shutter tie holes

Article number Dimensions mm

øD1

L

øD2FBVK22TTW Ø 42,6 x Ø 32,0 x 28

FBVKSKKTW Ø 59,0 x Ø 50,0 x 40

øD1

L

øD2FBVKZ22TW Ø 41,0 x Ø 21,6 x 22

FBVKZ22TTW Ø 42,6 x Ø 21,6 x 40

In Germany and many other countries

drinking water reservoir construc-

tions are mainly made of concrete.

The governing standard EN1508 and

the DVGW (The German Technical

and Scientifi c Association for Gas

and Water) standard W300 consider

that a high quality low porosity sur-

face is essential for hygienic reasons

and detail the principles to be taken

into account during the planning and

construction phases.

The DVGW data sheet W300 “planning

and construction of water reservoirs for

drinking water supply” recommends a

concrete impermeable to water and of

low porosity which does not require any

additional measures in terms of surface

treatment or lining. In order to avoid any

drinking water pollution, the materials

used in such applications have to be

approved to:

■ UBA guideline with regard to Epoxy re-

sin coatings, for hygienic assessment

of epoxy resin coatings in contact with

drinking water.

■ DVGW data sheet W347: “Hygienic re-

quirements on cement based materials

in drinking water applications” – for

cement based materials such as fi bre

concrete – corresponds with KTW

testing (migration test).

■ Testing according to DVGW data sheet

W270: “Test on microbiological growth

for materials used in drinking water

applications”. Materials in contact with

drinking water must not deteriorate the

microbiological condition of the water,

i.e. release agent residues which

could lead to micro organism growth.

In order to determine those materials

suitable for drinking water applications

this test is indispensable.

Repoxal TW – two-component glue

Article number Description

MREPOXTW Repoxal two-component glue(approved for impermeable joints in the drinkingwater sector, 0.75 kg per tin, 6 pieces/carton

Tested to DVGW-W270 and UBA guideline for epoxy resin coatings

Fibre concrete TW – tested to DVGW – W270 and DVGW-W347

As well as manufacturing spacers and sealing cones that comply with the DVGW regulations in Germany, Frank spacers are also manufactured and certifi ed to comply with the governing standards for products in contact with potable water in other countries. These standards include BS6920, SS375 and AS/NZS4020:2002.


FRANK Products fo r d r ink ing wate r app l i cat ions

Permur Monolith – a special mould for monolithic circular

chases cast in a concrete wall

Zemdrain® formwork liner – for uncontaminated, virtually

blowhole free, low porosity concrete surfaces.

For more detailed information on our products Permur Monolith and Zemdrain®

formwork liner please consult our brochures, which we will gladly send you on request;

or simply visit our Website www.maxfrank.com and download these documents.

FRANK products are approved for drinking water applications and

fulfi l these strict requirements. Their use in the drinking water sector

is permitted without any restrictions. It is therefore possible to build

impermeable drinking water structures.

36

Plastic product range Distance tubes and spacers

Plastic distance tubes

Plastic distance tube with roughened surface and plugged-in end

caps

■ Inner diameter of 22 mm for threaded steel ø 15 mm

■ Roughened outside for improved concrete bond

■ Supplied in variable lengths

Plastic distance tube with sealing stopper

Single-piece plastic distance tube – in stable design – with large

formwork support

■ Inner diameter of 22 mm for threaded steel ø 15 mm

■ Supplied in standard lengths for wall thicknesses from 0.20 – 0.40 m

Plastic ring spacers

For reinforcement ø 10 mm

■ Concrete cover from 15 - 50 mm

Millihax – plastic disk spacer

For horizontal reinforcement

■ Supplied in diameter range approx. 150 – 400 mm

■ Concrete cover from 15 to 30 mm

■ Easy installation


Plastic product range Spacers and prof i l es

U-Profile “with”

Supporting profiles with lateral notches

Linear plastic spacer for horizontal reinforcement

■ Concrete cover from 15 – 50 mm

■ Supplied in 2 metre lengths

U-Profile “without”

Supporting profi les for insulation without lateral notchesLinear plastic spacer for horizontal reinforcement on insulation

■ Concrete cover from 15 – 50 mm

■ Supplied in 2 metre lengths

■ The large supporting surface prevents the material from being pressed into

the insulation.

Wana – weather drip profile

Made of plastic

■ Available in standard sizes

■ Supplied in 2.50 metre lengths

■ The weather drip remains inside the concrete and thus forms a clear weather

drip edge without any cracks

Chamfer – triangular profilePlastic profi le for chamfered corners



■ Due to the profi le’s smooth surface it is easily removed with the formwork

Chamfer – triangular profile with flangePlastic profi le with fl ange for secure chamfered corners




Trapezoidal profile 10/20

Made of plastic

■ Dimension 20/10 mm



38

FRANK Test ce r t i f i cates

Article Number Test Certifi cates

Fibre concrete

Spacers and bar spacers made of fi bre-reinforced concrete

YPROS01019 Test on load at rupture - spacersIssued by Prof. Rehm, certifi cate no. 489/90

YPROS01054 Test on frost resistance according to DBV (German Concrete Association) data sheet “spacers” – requirement “F”Issued by the Institute for Material Testing in Leipzig, Germany

YPROS01066 Testing on alternating temperature resistance of concreted spacers according to DBV data sheet “spacers” – requirement “T”Issued by the Institute for Material Testing in Leipzig, Germany

YPROS01039 Test on water penetration depth on concreted spacers according to DBV data sheet “Spacers” – requirement “A”Issued by the Bavarian Trade Association, certifi cate no. BP0030004

YPROS01071 Test on water penetration depth on concreted spacers according to DBV data sheet “Spacers – requirement “A” bar spacers type FAHKS40Issued by the Institute for Material Testing in Leipzig, Germany

YPROS01072 Test on water penetration depth on concreted spacers according to DBV data sheet “Spacers” – requirement “A” spacers type AD 4013Issued by the Institute for Material Testing in Leipzig, Germany

YPROS01059 Test on behaviour under exposure to frost/de-icing agents for spacers, BE II FT visually, according to the D-R methodSpacers AD 30R6Z10 and FBSP5353506 LPM AG, Beinwill am See, Switzerland / Report no. A-28’129-2

YPROS01087 Cementitious spacer block extrusions compressive strength testing – Report 37284/F/1 – Sandberg LLP, London

YPROS01088 Cementitious spacer block extrusions durability testing for mix ST – Report 37284/F/2 – Sandberg LLP, London

YPROS01089 Cementitious spacer block extrusions durability testing for mix SS – Report 37284/F/3 – Sandberg LLP, London

YPROS01090 Cementitious spacer block extrusions durability testing for mix NOR – Report 37284/F/4 – Sandberg LLP, London

YPROS01102 NOR spacer mix chloride ion penetration test results – Report 39210/F – Sandberg LLP, London

Distance tubes made of fi bre-reinforced concrete

Test on water impermeabilitySealing with fi bre-concrete stoppers, tested to 5 bar, ø 22 mmProf. Dr.-Ing. Harald Sipple

YPROS01030

YPROS01031 Sealing with fi bre-concrete stoppers, tested to 5 bar, ø 32 mmProf. Dr.-Ing. Harald Sipple

YPROS01027 Sealing with fi bre-concrete stoppers, tested to 30 bar, ø 22 mm Prof. Teubert

YPROS01016 Sealing with FRANK special mortar 3/25 Issued by the Material Testing Institute of North Rhine Westphalia

YPROS01017 Test on load at rupture – distance tubes – Issued by Prof. Rehm, certifi cate no. 490/90

YPROS01050 Expert’s report on behaviour under fi re of reinforced concrete walls with distance tubesIssued by the Material Testing Institute of Civil Engineering at the Technical University of Braunschweig, Germany

YPROS01075 Expert’s report on infl uence of stoppers in distance tubes on the airborne sound insulation of a concrete wallIssued by the Institute for Material Testing in Leipzig, Germany

YPROS01014 Test on suitability for shelters Issued by the Federal Minister for Regional Planning, Civil Engineering and Urban Development

YPROS01022 Behaviour of Repoxal TW glue in contact with drinking water Issued by the Hygienic Institute of Gelsenkirchen, Germany, test certifi cate according to the UBA guideline “Hygienic evaluation of epoxy resin coatings in contact with drinking water”

YPROS01057 Repoxal glue for drinking water applications – Test on microbiological growth for materials in drinking water applicationsIssued by the Hygienic Institute of Gelsenkirchen, Germany, test certifi cate according to DVGW – W270

Fibre concrete TW

YPROS01053 Hygienic requirements on cement-based materials in drinking water applicationsIssued by the Hygienic Institute of Gelsenkirchen, Germany, test certifi cate according to DVGW data sheet W347

YPROS01055 Test certifi cate on microbiological growth on materials for drinking water applicationsIssued by Hygienic Institute of Gelsenkichen, Germany, test certifi cate according to DVGW data sheet W270

YPROS01085 Testing of non-metallic materials for use with drinking water (BS 6920) – Test report M104175 – WRC, UK


FRANK Refe rences

Advanced Technical College Frankfurt a. M.FRANK coloured sealing cones for exposed concrete surfaces

House of German Emigrants, BremerhavenFRANK spacers for exposed concrete surfaces

Museum, Island of Hombroich, NeussFRANK distance tubes and fi bre concrete sealing cones for exposed concrete surfaces

Allianz-Arena stadium, Munich FRANK bar spacers

Metro system, DubaiFRANK single spacers in special design

Photos: Max FRANK

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w w w. m a x f r a n k . c o m

Max Frank GmbH & Co. KG I Technologies for the construction industry

Mitterweg 1

94339 Leiblfi ng

Germany

Sales Department

Phone +49 9427 189-0

Fax +49 9427 1588

Technical consulting

Phone +49 9427 189-189

Fax +49 9427 189-160

[email protected]

www.maxfrank.com

Documents

FRANK Spacer Technology · FRANK ﬁ bre concrete spacers match all of the above requirements and more. Applications for Standard and Premium grade fibre-reinforced concrete spacers